Hinge-Line Actuator Gearset for Thin Composite Wing Torque Transfer

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Solution Overview

Problem

Existing hinge-line actuators for aircraft control surfaces face challenges in efficiently transferring torque without damaging the composite wing structure, particularly in thinly structured composite wings where spatial limitations are a concern.

Innovation Solution

The design incorporates a gearset with first and second ground gears and an output gear, configured to provide a compound differential gearing system. This system is housed in a composite actuator housing integrated into the control surface, utilizing contoured gear surfaces to mitigate material failure risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a hinge-line actuator is installed in a thinly structured composite wing, then the actuator can provide high-torque power transmission in a compact space, but the composite wing structure may be damaged due to torque transfer issues

Engineering Contradiction:

Improveactuator sizeVSAvoidcomposite wing structure integrity

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

A torque transfer mechanism comprising a drive shaft, a first gear, a second gear, and a output gear is introduced as an intermediary between the actuator motor and the control surface. This mechanism systematically transfers torque through multiple gear stages, distributing the torque load and preventing direct transmission that could damage the composite wing structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The gear ratio parameters are specifically designed to transform the motor's high-speed low-torque output into low-speed high-torque output suitable for moving the control surface. The first gear ratio and second gear ratio are configured to achieve the required torque multiplication while maintaining compatibility with the composite wing structure's load-bearing capacity.

Inventive Principle:

Principle #35Parameter changes

2Power

If a compound differential gearing system is used to provide high-torque power transmission, then the actuator can effectively rotate the control surface, but the gear configuration complexity increases

Engineering Contradiction:

Improvetorque transmission capabilityVSAvoidgear configuration

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The torque transmission system is segmented into distinct functional components: a drive shaft, a first gear mounted on the drive shaft, a second gear, and an output gear. Each component has a specific function, and they are arranged in a systematic sequence that simplifies the overall configuration while achieving compound differential gearing functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple gear stages are combined into a single integrated torque transfer mechanism that operates as a cohesive unit. The first gear and second gear work together with the output gear to achieve torque multiplication, merging multiple functional elements into a compact arrangement that reduces overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Weight of moving object

If the actuator housing is formed from a composite material, then the actuator weight is reduced and it integrates better with the composite wing, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveactuator weightVSAvoidactuator housing manufacturing

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The actuator housing is formed from composite material that matches the composite wing structure, providing weight reduction and structural integration. The composite housing is designed to accommodate all internal components including the torque transfer mechanism, and is manufactured as an integral structure that bonds with the wing's composite material, eliminating the need for separate fastening systems.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively transfers torque to the control surface while preventing damage to the composite wing structure, optimizing the use of available space and ensuring reliable operation.

Implementation Method 1

A hinge-line actuator utilizes compound differential gearing to provide high-torque, low-speed power transmission

Methodology Applied

Scientific EffectGear: Gear

Data Source

PatentEP4163518B1Hinge-line actuator for rotating an aircraft control surface

Publication Date: 2025.06.18 HAMILTON SUNDSTRAND CORP

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AI summary

A hinge-line actuator has: a drive shaft; first and second ground gears spaced apart along the drive shaft, wherein the first and second output gears include first and second contoured outer gear surfaces; and an output gear disposed on the drive shaft and disposed between the first and second ground gears, wherein the output gear includes a third contoured outer gear surface; an actuator housing that includes: contoured first, second and third gear seats that, respectively, seat the first, second and third outer gear surfaces.